Footwear sole structure having a fluid-filled chamber including a tensile member

ABSTRACT

A footwear sole structure having a fluid-filled chamber including a tensile member is provided. The fluid-filled chamber includes a first barrier sheet, a second barrier sheet and the tensile member. The first barrier sheet is formed from a first thermoplastic material. The second barrier sheet is attached to the first barrier sheet and is formed from a second thermoplastic material. The first barrier sheet and the second barrier sheet cooperate to define an internal cavity. The tensile member is disposed within the internal cavity and is formed from a third thermoplastic material. A first weld attaches the first barrier sheet, the second barrier sheet, and the tensile member together by melding the first thermoplastic material of the first barrier sheet, the second thermoplastic material of second barrier sheet, and the third thermoplastic material of the tensile member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application No. 62/470,019, filed Mar. 10, 2017 and to U.S.Provisional Application No. 62/621,378, filed on Jan. 24, 2018. Thedisclosures of these prior applications are considered part of thedisclosure of this application and are hereby incorporated by referencein their entireties.

FIELD

The present disclosure relates generally to articles of footwear andmore particularly to a sole structure for an article of footwear.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Articles of footwear conventionally include an upper and a solestructure. The upper may be formed from any suitable material(s) toreceive, secure, and support a foot on the sole structure. The upper maycooperate with laces, straps, or other fasteners to adjust the fit ofthe upper around the foot. A bottom portion of the upper, proximate to abottom surface of the foot, attaches to the sole structure.

Sole structures generally include a stacked arrangement extendingbetween a ground surface and the upper. One layer of the sole structureincludes an outsole that provides abrasion-resistance and traction withthe ground surface. The outsole may be formed from rubber or othermaterials that impart durability and wear-resistance, as well asenhancing traction with the ground surface. Another layer of the solestructure includes a midsole disposed between the outsole and the upper.While existing sole structures perform adequately for their intendedpurpose, improvements to sole structures are continuously being soughtin order to advance the arts.

DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of an article of footwear incorporating asole structure in accordance with the principles of the presentdisclosure;

FIG. 2 is a cross-sectional view of the article of footwear of FIG. 1taken along Line 2-2 of FIG. 1;

FIG. 3 is an exploded view of the article of footwear of FIG. 1;

FIG. 1A is a perspective view of an article of footwear incorporating asole structure in accordance with the principles of the presentdisclosure;

FIG. 2A is a cross-sectional view of the article of footwear of FIG. 1Ataken along Line 2A-2A of FIG. 1A;

FIG. 3A is an exploded view of the article of footwear of FIG. 1A;

FIG. 1B is a perspective view of an article of footwear incorporating asole structure in accordance with the principles of the presentdisclosure;

FIG. 2B is a cross-sectional view of the article of footwear of FIG. 1Btaken along Line 2B-2B of FIG. 1B;

FIG. 3B is an exploded view of the article of footwear of FIG. 1B;

FIG. 4 is an exemplary side view of the article of footwear of any ofFIGS. 1-3, FIGS. 1A-3A, or FIGS. 1B-3B;

FIG. 5 is an exemplary side view of the article of footwear of any ofFIGS. 1-3, FIGS. 1A-3A, or FIGS. 1B-3B;

FIG. 6 is an exemplary side view of the article of footwear of any ofFIGS. 1-3, FIGS. 1A-3A, or FIGS. 1B-3B;

FIG. 7 is an exemplary side view of the article of footwear of any ofFIGS. 1-3, FIGS. 1A-3A, or FIGS. 1B-3B;

FIG. 8 is an exploded view of a cushioning arrangement of the article offootwear of any of FIGS. 1-3, FIGS. 1A-3A, or FIGS. 1B-3B;

FIG. 9 is a cross-sectional view of the cushioning arrangement of FIG. 8taken along Line 9-9 of FIG. 8;

FIG. 10 is a cross-sectional view of the cushioning arrangement of FIG.9 arranged in a partially assembled state;

FIG. 11 is an enlarged cross-sectional view of a portion of thecushioning arrangement of FIG. 10 identified by Line 11 of FIG. 10;

FIG. 12 is a cross-sectional view of the cushioning arrangement of FIG.10 arranged in a further partially assembled state and taken along Line12-12 of FIG. 14;

FIG. 13 is an enlarged cross-sectional view of a portion of thecushioning arrangement of FIG. 12 identified by Line 13 of FIG. 12;

FIG. 14 is a perspective view of a partially assembled cushioningarrangement according to FIG. 12;

FIG. 15 is an enlarged cross-sectional view of a portion of thecushioning arrangement of FIG. 12 identified by Line 15 of FIG. 12;

FIG. 16 is a cross-sectional view of a portion of the cushioningarrangement of FIG. 15 arranged in a further assembled state and takenalong Line 16-16 of FIG. 17;

FIG. 17 is a perspective view of the cushioning arrangement of thearticle of footwear of either of FIGS. 1-3 or FIGS. 1B-3B;

FIG. 18 is a perspective view of a first mold tool arranged in an openconfiguration and the exploded view of a cushioning arrangement of FIG.8;

FIG. 19 is a side view of the first mold tool arranged in the openconfiguration and the cushioning arrangement of FIG. 18;

FIG. 20 is a side view of the first mold tool of FIG. 19 arranged in apartially closed configuration and the cushioning arrangement of FIG.19;

FIG. 21 is a side view of the first mold tool of FIG. 20 arranged in aclosed configuration and the cushioning arrangement of FIG. 20;

FIG. 22 is a schematic representation of a source of fluid providing thecushioning arrangement of FIG. 20 with pressurized fluid;

FIG. 23 is a perspective view of the first mold tool returned to theopen configuration from the closed configuration and the partiallyassembled cushioning arrangement of FIG. 14;

FIG. 24 is a perspective view of a second mold tool arranged in an openconfiguration and the partially assembled cushioning arrangement of FIG.14;

FIG. 25 is a side view of the second mold tool arranged in the openconfiguration and the cushioning arrangement of FIG. 14;

FIG. 26 is a side view of the second mold tool of FIG. 25 arranged in aclosed configuration and the cushioning arrangement of FIG. 25;

FIG. 27 is a perspective view of the second mold tool returned to openconfiguration from the closed configuration and the cushioningarrangement of FIG. 17;

FIG. 28 is a cross-sectional view of a portion of an exemplarycushioning arrangement;

FIG. 29 is a perspective view of an exemplary mold tool returned to anopen configuration from a closed configuration for forming thecushioning arrangement of FIG. 28;

FIG. 30 is a plan view of a lower half of the mold tool of FIG. 29;

FIG. 31 is a plan view of an upper half of the mold too of FIG. 29;

FIG. 32 is an exploded cross-sectional view of an exemplary cushioningarrangement;

FIG. 33 is a cross-sectional view of the cushioning arrangement of FIG.32 arranged in a partially assembled state;

FIG. 34 is an enlarged cross-sectional view of a portion of thecushioning arrangement of FIG. 33 identified by Line 34 of FIG. 33;

FIG. 35 is a cross-sectional view of the cushioning arrangement of FIG.33 arranged in a further partially assembled state;

FIG. 36 is an enlarged cross-sectional view of a portion of thecushioning arrangement of FIG. 35 identified by Line 36 of FIG. 35;

FIG. 37 is a cross-sectional view of a portion of the exemplarycushioning arrangement of FIG. 32-36 after being formed by a mold tool;

FIG. 38 is an exploded cross-sectional view of an exemplary cushioningarrangement;

FIG. 39 is a cross-sectional view of the cushioning arrangement of FIG.38 arranged in a partially assembled state;

FIG. 40 is an enlarged cross-sectional view of a portion of thecushioning arrangement of FIG. 39 identified by Line 40 of FIG. 39;

FIG. 41 is a cross-sectional view of the cushioning arrangement of FIG.39 arranged in a further partially assembled state;

FIG. 42 is an enlarged cross-sectional view of a portion of thecushioning arrangement of FIG. 41 identified by Line 42 of FIG. 41;

FIG. 43 is a cross-sectional view of a portion of the exemplarycushioning arrangement of FIG. 38-42 after being formed by a mold tool;

FIG. 44 is an exploded cross-sectional view of an exemplary cushioningarrangement;

FIG. 45 is a cross-sectional view of the cushioning arrangement of FIG.44 arranged in a partially assembled state;

FIG. 46 is an enlarged cross-sectional view of a portion of thecushioning arrangement of FIG. 45 identified by Line 46 of FIG. 45;

FIG. 47 is a cross-sectional view of the cushioning arrangement of FIG.45 arranged in a further partially assembled state;

FIG. 48 is an enlarged cross-sectional view of a portion of thecushioning arrangement of FIG. 47 identified by Line 48 of FIG. 47; and

FIG. 49 is a cross-sectional view of a portion of the exemplarycushioning arrangement of FIG. 44-48 after being formed by a mold tool.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

The present disclosure is directed to a fluid-filled chamber including atensile member. The fluid-filled chamber includes a first barrier sheet,a second barrier sheet, and the tensile member. The first barrier sheetis formed from a first thermoplastic material, the second barrier sheetis formed from a second thermoplastic material, and the tensile memberis formed from a third thermoplastic material. The second barrier sheetis attached to the first barrier sheet and the first barrier sheet andthe second barrier sheet cooperate to define an internal cavity. Thetensile member is disposed within the internal cavity. A first weldattaches the first barrier sheet, the second barrier sheet, and thetensile member together by melding the first thermoplastic material ofthe first barrier sheet, the second thermoplastic material of secondbarrier sheet, and the third thermoplastic material of the tensilemember. The fluid-filled chamber can be used in footwear as a cushioningelement, such as, for example, as a sole structure or a component of asole structure or as a heel counter. The fluid-filled chamber can alsobe used as a cushioning element in apparel. The fluid-filled chamber canalso be used in sporting equipment as a cushioning element, such as, forexample, in the straps of a backpack. The present disclosure is alsodirected to methods of forming the fluid-filled chambers as describedherein, as well as methods of manufacturing footwear, apparel, or sportsequipment comprising incorporating the fluid-filled chamber into sucharticles.

The melding of the first thermoplastic material, the secondthermoplastic material, and the third thermoplastic material can beproduced by softening all three thermoplastic materials, therebyallowing all three thermoplastic materials to co-mingle at leastpartially at the location of the first weld and then re-solidify. In sodoing, the barrier sheets and the tensile member are no longer separatecomponents at the location of the first weld. Use of such melded firstwelds allows fluid-filled chambers with new configurations to be made.For example, use of such melded first welds allows for the design andproduction of fluid-filled chambers that are more flexible and/or thathave a greater degree of curvature as compared to fluid-filled chamberswithout such melded welds.

Example embodiments will now be described more fully with reference tothe accompanying drawings. Example embodiments are provided so that thisdisclosure will be thorough, and will fully convey the scope of thosewho are skilled in the art. Numerous specific details are set forth suchas examples of specific components, devices, and methods, to provide athorough understanding of embodiments of the present disclosure. It willbe apparent to those skilled in the art that specific details need notbe employed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of modedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or sheet is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or sheet, it may bedirectly on, engaged, connected or coupled to the other element orsheet, or intervening elements or sheets may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor sheet, there may be no intervening elements or sheets present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, sheets and/or sections,these elements, components, regions, sheets and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, sheet or section from another region,sheet or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,sheet or section discussed below could be termed a second element,component, region, sheet or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

With reference to the figures, a fluid-filled chamber is provided. Thefluid-filled chamber includes a first barrier sheet, a second barriersheet, and a tensile member. The first barrier sheet is formed from afirst thermoplastic material. The second barrier sheet is attached tothe first barrier sheet and is formed from a second thermoplasticmaterial. The first barrier sheet and the second barrier sheet cooperateto define an internal cavity. The tensile member is disposed within theinternal cavity and is formed from a third thermoplastic material. Afirst weld attaches the first barrier sheet, the second barrier sheet,and the tensile member together by melding the first thermoplasticmaterial of the first barrier sheet, the second thermoplastic materialof second barrier sheet, and the third thermoplastic material of thetensile member.

The first barrier sheet comprises the first thermoplastic material. Thefirst thermoplastic material comprises one or more polymers such as, forexample, one or more thermoplastic polyurethane (TPU) polymers. In someimplementations, the first barrier sheet can be a layered film formed ofmultiple layers of thermoplastic materials. The multiple layers can beformed of multiple thermoplastic materials including the firstthermoplastic material. In such examples, the melting point(s) of themultiple thermoplastic materials is less than, or approximately the sameas, the melting point of the first thermoplastic material. In oneexample, the first barrier sheet can comprise layers of the firstthermoplastic material with a different thermoplastic material. Thefirst thermoplastic material can comprise one or more TPU polymers, andthe different thermoplastic materials can comprise one or moreethylene-vinyl alcohol (EVOH) polymers. In a particular example, whenthe first barrier sheet comprises multiple layers of thermoplasticmaterials including one or more layers of the first thermoplasticmaterial, a polymeric component of the first thermoplastic material canconsist essentially of one or more TPU polymers. Similarly, the secondbarrier sheet comprises the second thermoplastic material. The secondthermoplastic material comprises one or more polymers such as, forexample, one or more thermoplastic polyurethane (TPU) polymers. In someimplementations, the second barrier sheet can be a layered film formedof multiple layers of thermoplastic materials. The multiple layers canbe formed of multiple thermoplastic materials including the secondthermoplastic material. In such examples, the melting point(s) of themultiple thermoplastic materials is less than, or approximately the sameas, the melting point of the second thermoplastic material. In oneexample, the second barrier sheet can comprise layers of the secondthermoplastic material with a different thermoplastic material. Thesecond thermoplastic material can comprise one or more TPU polymers, andthe different thermoplastic materials can comprise one or moreethylene-vinyl alcohol (EVOH) polymers. In a particular example, whenthe second barrier sheet comprises multiple layers of thermoplasticmaterials including one or more layers of the second thermoplasticmaterial, a polymeric component of the second thermoplastic material canconsist essentially of one or more TPU polymers.

In one configuration, a second weld extends continuously around aperimeter of the fluid-filled chamber to define an outer edge of thefluid-filled chamber. The second weld may join the first barrier sheetand the second barrier sheet and, further, may be spaced apart from thefirst weld. Alternatively, the first weld may contact and extend fromthe second weld.

In some implementations, the third thermoplastic material of the tensilemember is foamed and, further, may be formed from a sheet of foamedthermoplastic material.

The tensile member may include a plurality of tensile elements extendingbetween the first barrier sheet and the second barrier sheet. Theplurality of tensile elements may extend between and connect a firsttensile layer that opposes the first barrier sheet and a second tensilelayer that opposes the second barrier sheet. In other examples, thefirst tensile layer may be attached to the first barrier sheet and thesecond tensile layer may be attached to the second barrier sheet.

In one configuration, the tensile member comprises a textile. The fibersor yarns from which the textile is formed can themselves be formed ofthe third thermoplastic material. For example, substantially all of thefibers and/or yarns forming the textile can consist essentially of thethird thermoplastic material. Alternatively, substantially all of thefibers and/or yarns forming the textile can be formed of one or morethermoplastic materials each having a melting point within a range ofabout 20° C. or about 10° C. or about 5° C. of the melting points of thefirst thermoplastic material and the second thermoplastic material ofthe first barrier sheet and the second barrier sheet. In anotherexample, substantially all of the fibers and/or yarns forming thetextile can be formed of one or more thermoplastic materials each havinga melting point less than the melting points of the first thermoplasticmaterial and the second thermoplastic material, or less than about 10°C. or about 5° C. greater than the melting points of the firstthermoplastic material and the second thermoplastic material.

The textile may be a knit textile. The knit textile may include a firsttensile layer, a second tensile layer, and tensile strands extendingbetween and connecting the first tensile layer and the second tensilelayer. For example, the knit textile can be a warp knit spacer fabricformed of one or more yarns. Each of the one or more yarns can be formedof the third thermoplastic material, or can be formed of a thermoplasticmaterial having a melting point within a range of about 20° C. or ofabout 10° C. or of about 5° C. of the melting points of the firstthermoplastic material and the second thermoplastic material of thefirst barrier sheet and the second barrier sheet. In a particularexample, each of the one or more yarns can be formed of a thermoplasticmaterial comprising one or more thermoplastic polyurethane (TPU)polymers. The first tensile layer may oppose the first barrier sheet andthe second tensile layer may oppose the second barrier sheet. The firsttensile layer may be attached to the first barrier sheet and the secondtensile layer may be attached to the second barrier sheet.

In some implementations, the internal cavity receives a pressurizedfluid. In an example, the pressurized fluid is air.

The first thermoplastic material, the second thermoplastic material, andthe third thermoplastic material can comprise one or more thermoplasticpolyurethane (TPU) polymers. In an example, a melting temperature of thefirst thermoplastic material, a melting temperature of the secondthermoplastic material, and a melting temperature of the thirdthermoplastic material are all within a range of approximately 20° C.,or are all within a range of approximately 10° C., or are all within arange of approximately 5° C. In other examples, a melting temperature ofthe first thermoplastic material, a melting temperature of the secondthermoplastic material, and a melting temperature of the thirdthermoplastic material are approximately the same. In yet otherexamples, at least two of the first thermoplastic material, the secondthermoplastic material, and the third thermoplastic material are formedfrom the same material.

In some configurations, an article of footwear incorporates thefluid-filled chamber. In other configurations, an article of equipmentmay include the fluid-filled chamber.

With reference to the figures, a method of making a fluid-filled chamberis provided. The method includes receiving a first barrier sheet formedfrom a first thermoplastic material, receiving a second barrier sheetformed from a second thermoplastic material, and receiving a tensilemember formed from a third thermoplastic material. The tensile member ispositioned between the first barrier sheet and the second barrier sheet.The first barrier sheet, the second barrier sheet, and the tensilemember are welded together at a first weld by melding the firstthermoplastic material of the first barrier sheet, the secondthermoplastic material of second barrier sheet, and the thirdthermoplastic material of the tensile member.

In some examples, the method may include forming a second weld thatextends continuously around a perimeter of the fluid-filled chamber todefine an outer edge of the fluid-filled chamber. The second weld mayextend continuously around a perimeter of the fluid-filled chamber andmay join the first barrier sheet and the second barrier sheet. Weldingthe first barrier sheet, the second barrier sheet, and the tensilemember together at the first weld may include spacing the first weldapart from the second weld. Alternatively, welding the first barriersheet, the second barrier sheet, and the tensile member together at thefirst weld may include contacting the first weld with the second weldsuch that the first weld extends from the second weld.

In some instances, forming the tensile member from the thirdthermoplastic material includes forming the tensile member from a foamedthermoplastic material and, further, may include forming the tensilemember from a sheet of foamed thermoplastic material. Forming thetensile member from the third thermoplastic material may includeproviding the tensile member with a plurality of tensile elementsextending between the first barrier sheet and the second barrier sheet.Providing the tensile member with a plurality of tensile elements mayinclude extending the plurality of tensile elements between a firsttensile layer that opposes the first barrier sheet and a second tensilelayer that opposes the second barrier sheet, the plurality of tensileelements connecting the first tensile layer and the second tensilelayer. The method may additionally include attaching the first tensilelayer to the first barrier sheet and attaching the second tensile layerto the second barrier sheet.

In some implementations, forming the tensile member from the thirdthermoplastic material may include forming the tensile member from atextile such as, for example, a knit textile. Forming the tensile memberfrom a knit textile may include forming the knit textile to include afirst tensile layer, a second tensile layer, and tensile strands thatextend between and connect the first tensile layer and the secondtensile layer. The method may include positioning the tensile membersuch that the first tensile layer opposes the first barrier sheet andthe second tensile layer opposes the second barrier sheet. The methodmay also include attaching the first tensile layer to the first barriersheet and attaching the second tensile layer to the second barriersheet.

In some examples, the method includes providing an internal cavity ofthe fluid-filled chamber with a pressurized fluid. Providing theinternal cavity with a pressurized fluid may include providing theinternal cavity with pressurized air.

In some instances, forming the first barrier sheet from a firstthermoplastic material, forming the second barrier sheet from a secondthermoplastic material, and forming the tensile member from a thirdthermoplastic material includes forming the first barrier sheet, thesecond barrier sheet, and the tensile member from one or morethermoplastic polyurethane (TPU) polymers. In other instances, formingthe first barrier sheet from a first thermoplastic material, forming thesecond barrier sheet from a second thermoplastic material, and formingthe tensile member from a third thermoplastic material includes formingthe first barrier sheet, the second barrier sheet, and the tensilemember from materials having melting temperatures that are all within arange of approximately 20° C. In yet other instances, forming the firstbarrier sheet from a first thermoplastic material, forming the secondbarrier sheet from a second thermoplastic material, and forming thetensile member from a third thermoplastic material includes forming thefirst barrier sheet, the second barrier sheet, and the tensile memberfrom materials having melting temperatures that are approximately thesame. Forming the first barrier sheet from a first thermoplasticmaterial, forming the second barrier sheet from a second thermoplasticmaterial, and forming the tensile member from a third thermoplasticmaterial may include forming at least two of the first barrier sheet,the second barrier sheet, and the tensile member from the same material.

In some implementations, the method may include incorporating thefluid-filled chamber into an article of footwear. In otherimplementations, the method may include incorporating the fluid-filledchamber into an article of equipment.

With reference to FIGS. 1-3, an exemplary article of footwear 10 isprovided and includes an upper 12 and a sole structure 14 attached tothe upper 12. The article of footwear 10 may be divided into one or moreregions. The regions may include a forefoot region 16, a midfoot region18, and a heel region 20. The forefoot region 16 may correspond withtoes and joints connecting metatarsal bones with phalanx bones of afoot. The midfoot region 18 may correspond with an arch area of the footwhile the heel region 18 may correspond with rear portions of the foot,including a calcaneus bone. The article of footwear 10 may additionallyinclude a medial side 22 and a lateral side 24 that correspond withopposite sides of the article of footwear 10 and extend through theregions 16, 18, and 20. The sole structure 14 may include a midsole 26,an outsole 28, and a cushioning arrangement 30. The cushioningarrangement 30 is disposed generally between the upper 12 and theoutsole 28 and may be supported by the midsole 26, whereby a material ofthe midsole 26 is disposed between the cushioning arrangement 30 and theupper 12 and/or is disposed between the cushioning arrangement 30 andthe outsole 28.

With reference to FIGS. 1A-3A, another exemplary article of footwear 10a is provided and includes an upper 12 a and a sole structure 14 aattached to the upper 12 a. As with the article of footwear 10, thearticle of footwear 10 a may be divided into one or more regions. Theregions may include a forefoot region 16 a, a midfoot region 18 a, and aheel region 20 a. The forefoot region 16 a may correspond with toes andjoints connecting metatarsal bones with phalanx bones of a foot. Themidfoot region 18 a may correspond with an arch area of the foot whilethe heel region 18 a may correspond with rear portions of the foot,including a calcaneus bone. The article of footwear 10 a mayadditionally include a medial side 22 a and a lateral side 24 a thatcorrespond with opposite sides of the article of footwear 10 a andextend through the regions 16 a, 18 a, and 20 a. The sole structure 14 amay include a midsole 26 a, an outsole 28 a, and a cushioningarrangement 30 a. The cushioning arrangement 30 a is disposed generallybetween the upper 12 a and the outsole 28 a and may be supported by themidsole 26 a, whereby a material of the midsole 26 a is disposed betweenthe cushioning arrangement 30 a and the upper 12 a and/or is disposedbetween the cushioning arrangement 30 a and the outsole 28 a.

With reference to FIGS. 1B-3B, yet another exemplary article of footwear10 b is provided and includes an upper 12 b and a sole structure 14 battached to the upper 12 b. The article of footwear 10 b may be dividedinto one or more regions. The regions may include a forefoot region 16b, a midfoot region 18 b, and a heel region 20 b. The forefoot region 16b may correspond with toes and joints connecting metatarsal bones withphalanx bones of a foot. The midfoot region 18 b may correspond with anarch area of the foot while the heel region 18 b may correspond withrear portions of the foot, including a calcaneus bone. The article offootwear 10 b may additionally include a medial side 22 b and a lateralside 24 b that correspond with opposite sides of the article of footwear10 b and extend through the regions 16 b, 18 b, and 20 b. The solestructure 14 b may include a midsole 26 b, an outsole 28 b, and acushioning arrangement 30 b. The cushioning arrangement 30 b is disposedgenerally between the upper 12 b and the outsole 28 b and may besupported by the midsole 26 b, whereby a material of the midsole 26 b isdisposed between the cushioning arrangement 30 b and the upper 12 band/or is disposed between the cushioning arrangement 30 b and theoutsole 28 b.

As shown in FIGS. 1-3 and 1A-3A, the outsole 28, 28 a extends acrosssubstantially the entire width (W₁₄) and the length (L₁₄) of the solestructures 14, 14a. However, comparatively, as shown in FIGS. 1B-3B,although the outsole 28 b extends across substantially the entire width(W₁₄) of the sole structure 14 b, the outsole 28 b is periodicallyinterrupted along the length (L₁₄) of the sole structure 14. As such,the outsole 28 b defines a plurality of pad portions that respectivelycorrespond to a portion of an outer surface profile of the cushioningarrangement 30 b, as shown in FIGS. 2B and 3B. Because the outsole 28 bis periodically interrupted, the cushioning arrangement 30 b is notobscured or covered by the outsole 28 b in areas between adjacent padportions of the outsole 28 b and is visible at the outsole 28 b in theseareas.

With particular reference to FIGS. 4-7, various locations of thecushioning arrangement 30 relative to the midsole 26 are provided. Whilethe location of the cushioning arrangement 30 relative to the midsole 26will be described and shown with respect to FIGS. 4-7, it should beunderstood that the cushioning arrangements 30 a, 30 b could be locatedin the same locations as the cushioning arrangement 30 relative to therespective midsoles 26 a, 26 b.

As shown in FIGS. 2 and 4, the cushioning arrangement 30 may extendacross substantially most or all of a length (L₁₄) of the sole structure14 including, for example, the forefoot region 16, the midfoot region18, and the heel region 20. In another example, as shown in FIG. 5, thecushioning arrangement 30 may extend across some or all of the heelregion 20 of the sole structure 14 but may not extend into the forefootregion 16 and the midfoot region 18 of the sole structure 14. In yetanother example, as shown in FIG. 6, the cushioning arrangement 30 mayextend across some or all of the forefoot region 16 of the solestructure 14 but may not extend into the midfoot region 18 and the heelregion 20 of the sole structure 14. Finally, as shown in in FIG. 7, thecushioning arrangement 30 may include a first portion extending acrosssome or all of the forefoot region 16 and a second portion extendingacross some or all of the heel region 20 with a material of the midsole26 disposed between and separating the first portion and the secondportion of the cushioning arrangement 30 at the midfoot region 18 of thesole structure 14. The cushioning arrangement 30 may additionally extendacross substantially all of a width (W₁₄) of the sole structure 14(FIG. 1) between the medial side 22 and the lateral side 24.

Referring, respectively, to FIGS. 1-3 and 1B-3B, the outer surfaceprofile of the cushioning arrangement 30 and the cushioning arrangement30 b may be substantially similar to one another. Therefore, althoughthe following disclosure at FIGS. 8-17 makes reference to the cushioningarrangement 30 of FIGS. 1-3, the disclosure at FIGS. 8-17 may also applyto the cushioning arrangement 30 b of FIGS. 1B-3B. Furthermore, althoughthe outer surface profile of the cushioning arrangement 30 a at FIGS.1A-3A is different from that of the outer surface profile of thecushioning arrangements 30, 30 b, aspects (see, for example, theformation of one or more recesses, trenches, or valleys 56) of thecushioning arrangement 30 described at FIGS. 8-17 also apply to thecushioning arrangement 30 a.

As shown in FIGS. 8-11, the cushioning arrangement 30 is defined by aplurality of components 32, 34, 36. When the plurality of components 32,34, 36 are joined together, as shown, for example, in FIGS. 12-15, theplurality of components 32, 34, 36 form a fluid-filled chamber 38.

As will be described in detail below, after the fluid-filled chamber 38is formed, the plurality of components 32, 34, 36 defining thecushioning arrangement 30 may be further shaped to divide thefluid-filled chamber 38 into a plurality of fluid-filled chambers 38₁-38 _(n). For example, the fluid-filled chambers 38 ₁-38 _(n) may bedefined by a rearward-most fluid-filled chamber 38 ₁ (see, e.g. FIGS. 16and 17) located within the heel region 20 of the sole structure 14 and aforward-most fluid-filled chamber 38 _(n) (see, for example, FIG. 17)located within the forefoot region 16 of the sole structure 14. Theplurality of fluid-filled chambers 38 ₁-38 _(n) may also be defined byone or more intermediate fluid-filled chambers 38 ₂-38 _(n-1) (see, forexample, FIG. 17) located between the fluid-filled chamber 38 ₁ and thefluid-filled chamber 38 _(n).

The shape of the fluid-filled chambers 38 ₁-38 _(n) define an outersurface profile of the cushioning arrangements 30, 30 a, 30 b. In anexample, as shown in FIGS. 3, 3B, and 17, each fluid-filled chamber ofthe plurality of fluid-filled chambers 38 ₁-38 _(n) extends laterallybetween the medial side 22, 22 b and the lateral side 24, 24 b of thesole structure 14, 14 b such that each fluid-filled chamber 38 ₁-38 _(n)includes a substantially rectangular shape having a longitudinal axisextending between the medial side 22, 22 b and the lateral side 24, 24b. In another example, as shown in FIG. 3A, each fluid-filled chamber ofthe plurality of fluid-filled chambers 38 ₁-38 _(n) may be defined by asubstantially hexagonal shape that collectively forms, for example, ahoneycomb pattern. While the chambers 38 ₁-38 _(n) could be elongate(FIGS. 3, 3B) or hexagonal (FIG. 3A), the chambers 38 ₁-38 _(n) couldinclude any shape, as will be described below.

Referring to FIGS. 8 and 9, an unassembled, exploded view of theplurality of components 32, 34, 36 defining an exemplary cushioningarrangement 30 is shown. The plurality of components 32, 34, 36 mayinclude a first barrier sheet 32, a second barrier sheet 34, and atensile member 36. The tensile member 36 may include a first tensilelayer 40, a second tensile layer 42, and a plurality of tensile elements44 extending between and connecting the first tensile layer 40 and thesecond tensile layer 42.

As shown generally in FIG. 8, each of the first barrier sheet 32 and thesecond barrier sheet 34 may be defined by an inner surface 32 _(I), 34_(I) and an outer surface 32 _(O), 34 _(O). Each of the first tensilelayer 40 and the second tensile layer 42 may also be defined by an innersurface 40 _(I), 42 _(I) and an outer surface 40 _(O), 42 _(O). Theplurality of tensile elements 44 extend between the inner surface 40_(I), 42 _(I) of each of the first tensile layer 40 and the secondtensile layer 42 to connect the first tensile layer 40 and the secondtensile layer 42.

With reference to FIG. 9, the inner surface 32 _(I) of the first barriersheet 32 may include a perimeter inner surface portion 32 _(I-P), afirst inner surface portion 32 _(I-1) extending from the perimeter innersurface portion 32 _(I-P), and a second inner surface portion 32 _(I-2)extending from the first inner surface portion 32 _(I-1). The innersurface 34 _(I) of the second barrier sheet 34 may include a perimeterinner surface portion 34 _(I-P), a first inner surface portion 34 _(I-1)extending from the perimeter inner surface portion 34 _(I-P), and asecond inner surface portion 34 _(I-2) extending from the first innersurface portion 34 _(I-1).

Referring to FIGS. 9-11, a first step of forming the exemplarycushioning arrangement 30 includes: (1) attaching the outer surface 40_(O) of the first tensile layer 40 of the tensile member 36 to thesecond inner surface portion 32 _(I-2) of the inner surface 32 _(I) ofthe first barrier sheet 32 by melding the material of the first tensilelayer 40 and the material of the first barrier sheet 32 to form a firstmelded portion 46 (see, for example, FIGS. 11) and (2) attaching theouter surface 42 _(O) of the second tensile layer 42 of the tensilemember 36 to the second inner surface portion 34 ₁₋₂ of the innersurface 34 ₁ of the second barrier sheet 34 by melding the material ofthe second tensile layer 42 and the material of the second barrier sheet34 to form a second melded portion 48 (see, for example, FIG. 11). Withreference to FIG. 11, the first melded portion 46 may include a portionof a thickness (T₃₂) of the first barrier sheet 32 and a portion of athickness (T₄₀) of the first tensile layer 40 of the tensile member 36.Similarly, the second melded portion 48 may include a portion of athickness (T₃₄) of the second barrier sheet 34 and a portion of athickness (T₄₂) of the second tensile layer 42 of the tensile member 36.

Melding of the materials of the first tensile layer 40 and the firstbarrier sheet 32 and melding of the materials of the second tensilelayer 42 and the second barrier sheet 34 may be accomplished by applyingheat to the first barrier sheet 32 and the second barrier sheet 34 tocause the materials of the foregoing elements 32, 34, 40, 42 to flow andmeld. While the foregoing elements 32, 34, 40, 42 are described andshown as being attached together by melding the materials of the firstbarrier sheet 32 and the first tensile layer 40 and by melding thematerials of the second barrier sheet 34 and the second tensile layer42, the first barrier sheet 32 and the second barrier sheet 34 couldalternatively be attached to the tensile layers 40, 42, respectively,via an adhesive (not shown) disposed between the first barrier sheet 32and the first tensile layer 40 and between the second barrier sheet 34and the second tensile layer 42.

As shown in FIGS. 10 and 11, after attaching the first tensile layer 40of the tensile member 36 to the first barrier sheet 32 and attaching thesecond tensile layer 42 of the tensile member 36 to the second barriersheet 34, the perimeter inner surface portion 32 _(I-P)and the firstinner surface portion 32 _(I-I) of the first barrier sheet 32 and theperimeter inner surface portion 34 _(1-P) and the first inner surfaceportion 34 _(I-1) of the second barrier sheet 34 are not attached to anyportion of the tensile member 36. At this point, a cavity 50 is definedbetween the first barrier sheet 32 and the second barrier sheet 34 butis not sealed from the surrounding environment.

With reference to FIGS. 12 and 13, the cavity 50 is subsequently sealedas a result of securing the perimeter inner surface portion 32 _(I-P)ofthe first barrier sheet 32 to the perimeter inner surface portion 34_(I-P) of the second barrier sheet 34. In so doing, a perimeter seal orweld 52 is formed and the cavity 50 is sealed to form the fluid-filledchamber 38.

Securing the perimeter inner surface portion 32 _(I-P)of the firstbarrier sheet 32 to the perimeter inner surface portion 34 _(I-P) of thesecond barrier sheet 34 to form the perimeter seal 52 may beaccomplished by heating or ultrasonically welding the perimeter innersurface portion 32 _(I-P) of the first barrier sheet 32 to the perimeterinner surface portion 34 _(I-P) of the second barrier sheet 34. Heatingor ultrasonically welding the perimeter inner surface portion 32_(I-P)of the first barrier sheet 32 to the perimeter inner surfaceportion 34 _(I-P) of the second barrier sheet 34 may result in one ormore of the perimeter inner surface portion 32 _(I-P)of the firstbarrier sheet 32 and the perimeter inner surface portion 34 _(I-P) ofthe second barrier sheet 34 being melted, melded, bonded, adhered orotherwise secured or connected together in a substantially airtight orsealed manner.

While the tensile member 36 is described as being attached to the firstbarrier sheet 32 and the second barrier sheet 34 prior to formation ofthe perimeter seal 52, the barrier sheets 32, 34 could alternatively beattached to the tensile member 36 contemporaneously with formation ofthe perimeter seal 52. For example, the tensile member 36 may bedisposed between the first barrier sheet 32 and the second barrier 34sheet and may be adhered to the sheets 32, 34—via an adhesive or viaheat by melding materials of the respective sheets 32, 34 and layers 40,42—at the same time heat is applied to form the perimeter seal 52.

Regardless of when the tensile member 36 is attached to the barriersheets 32, 34 (i.e., before or after formation of the perimeter seal52), the sealed cavity 50 may receive a pressurized fluid (e.g., air) toat least partially inflate the cavity 50 and place the tensile elements44 in tension. Placing the tensile elements 44 in tension causes thetensile elements 44 to restrict movement of the barrier sheets 32, 34 ina direction away from one another beyond a predetermined amount due toopposing ends of the tensile elements 44 being respectively connected tothe inner surface 40 _(I), 42 _(I) of each of the first tensile layer 40and the second tensile layer 42. In so doing, the tensile elements 44serve to maintain a desired outer shape of the fluid-filled chamber 38.

As shown in FIG. 13, after the perimeter seal 52 is formed by securingthe perimeter inner surface portion 32 _(I-P) of the first barrier sheet32 to the perimeter inner surface portion 34 _(I-P) of the secondbarrier sheet 34, the first inner surface portion 32 _(I-1) of the firstbarrier sheet 32 and the first inner surface portion 34 _(I-1) of thesecond barrier sheet 34 are not secured to any portion of the pluralityof components 32, 34, 36 defining the cushioning arrangement 30. As aresult, the first inner surface portion 32 _(I-1) of the first barriersheet 32 is arranged at a first spaced-apart distance (D1) from thefirst inner surface portion 34 _(I-1) of the second barrier sheet 34.Similarly, as shown in FIG. 13, because the tensile elements 44 arerespectively connected to and disposed between the inner surface 40_(I), 42 _(I) of each of the first tensile layer 40 and the secondtensile layer 42 and the cavity 50 is pressurized, the inner surface 40_(I) of the first tensile layer 40 is spaced-apart from the innersurface 42 _(I) of the second tensile layer 42 a second spaced apartdistance (D2).

With reference to FIG. 14, the outer surface profile of the cushioningarrangement 30 is generally defined by the outer surface 32 _(O) of thefirst barrier sheet 32 and the outer surface 34 _(O) of the secondbarrier sheet 34. Because the fluid-filled chamber 38 of the cushioningarrangement 30 of FIG. 14 is not yet shaped or divided into a pluralityof fluid-filled chambers 38 ₁-38 _(n), the outer surface 32 _(O), 34_(O) of each of the first barrier sheet 32 and the second barrier sheet34 remains substantially flat and smooth.

Referring to FIG. 15, in addition to the second spaced apart distance(D2), the inner surface 40 _(I) of the first tensile layer 40 may befurther defined as being spaced-apart from the inner surface 42 _(I) ofthe second tensile layer 42 at a third spaced apart distance (D3). Asdescribed above, during the manufacture of the cushioning arrangement30, the fluid-filled chamber 38 of the cushioning arrangement 30 may beshaped or divided into a plurality of fluid-filled chambers 38 ₁-38_(n). In an example, as shown comparatively in FIGS. 15 and 16,formation of the plurality of fluid-filled chambers 38 ₁-38 _(n), mayresult from disposing one or more portions of the inner surface 40 _(I)of the first tensile layer 40 adjacent one or more portions of the innersurface 42 _(I) of the second tensile layer 42 such that the thirdspaced apart distance (D3) is eliminated or reduced to zero (FIG. 16).

As shown in FIG. 16, when the third spaced apart distance (D3) iseliminated or reduced to zero, a region (see, for example, “R₅₄”) isdefined where the opposing portions of the inner surface 40 _(I) of thefirst tensile layer 40 and the inner surface 42 _(I) of the secondtensile layer 42 along with any tensile fibers 44 extending therebetweenare joined together. Specifically, the materials of the first barriersheet 32, the second barrier sheet 34, the first tensile layer 40, thesecond tensile layer 42, and the tensile elements 44 are melded togetherto form a third melded portion 54. The third melded portion 54 fuses orwelds the materials of the first barrier sheet 32, the second barriersheet 34, the first tensile layer 40, the second tensile layer 42, andthe tensile elements 44 together to form a series of internal welds(i.e., welds that are located within the perimeter seal or weld 52). Aswill be described below, the materials of these elements 32, 34, 40, 42,44 are melded together by applying heat to one or both of the firstbarrier sheet 32 and the second barrier sheet 34 at discrete locationsof the outer surfaces 32 _(O), 34 _(O) of each of the first barriersheet 32 and the second barrier sheet 34, respectively, to cause thematerials of these elements 32, 34, 40, 42, 44 to flow and meld.

Although one third melded portion 54 is shown at FIG. 16, a plurality ofthird melded portions 54 may be formed for further shaping or diving thefluid-filled chamber 38 of the cushioning arrangement 30 into theplurality of fluid-filled chambers 38 ₁-38 _(n). With reference to FIG.17, because the fluid-filled chamber 38 of the cushioning arrangement 30of FIGS. 16 and 17 is shaped or divided into a plurality of fluid-filledchambers 38 ₁-38 _(n), the outer surface 32 _(O), 34 _(O) of each of thefirst barrier sheet 32 and the second barrier sheet 34 no longer appearssubstantially flat and smooth. Rather, the outer surfaces 32 _(O), 34_(O) of each of the first barrier sheet 32 and the second barrier sheet34 are shaped to include one or more recesses, trenches, or valleys 56.The shape and locations of the valleys 56 provide the cushioningarrangements 30, 30 b with the elongate fluid-filled chambers 38 ₁-38_(n) and provide the cushioning arrangement 30 a with the fluid-filledchambers 38 ₁-38 _(n), having a hexagonal shape.

Referring to FIGS. 11 and 16, the first melded portion 46, the secondmelded portion 48, and the one or more third melded portion(s) 54 mayresult from at least two of: (1) the first barrier sheet 32; (2) thesecond barrier sheet 34; and (3) at least one of the components of thetensile member 36 (i.e., the first tensile layer 40, the second tensilelayer 42, and the plurality of tensile elements 44) being formed fromthe same material, a similar material, or a species of materialcorresponding to a genus material. In an example, the same material orthe similar material may be a thermoplastic polyurethane (TPU) polymer.In another example, the genus material may be a thermoplastic material.

In an example, the first barrier sheet 32, the second barrier sheet 34,and at least one of the components of the tensile member 36 may beformed from the following materials: (1) the first barrier sheet 32 maybe formed from a first thermoplastic material, (2) the second barriersheet 34 may be formed from a second thermoplastic material, and (3) thetensile member 36—including the first tensile layer 40, the secondtensile layer 42, and/or the tensile elements 44—may be formed from athird thermoplastic material (e.g., the first, second, and thirdthermoplastic materials may be the same material or, alternatively,different thermoplastic material species of a genus of a thermoplasticmaterial). In an example, a melting temperature of the firstthermoplastic material, a melting temperature of the secondthermoplastic material, and a melting temperature of the thirdthermoplastic material are all within a range of approximately 20° C. Inanother example, a melting temperature of the first thermoplasticmaterial, a melting temperature of the second thermoplastic material,and a melting temperature of the third thermoplastic material areapproximately the same.

In addition to the foregoing material properties, the material definingthe tensile member 36—including the first tensile layer 40, the secondtensile layer 42, and/or the tensile elements 44—may be a foamedmaterial such as a sheet of foamed thermoplastic material.Alternatively, the material defining the tensile member 36—including thefirst tensile layer 40, the second tensile layer 42, and/or the tensileelements 44—may be a textile such as a knit textile having tensilestrands forming the tensile elements 44.

Referring to FIGS. 18-23, a first mold tool 58 is shown for forming thecushioning arrangement 30 of FIG. 14. As shown in FIG. 18, the mold tool58 includes an upper mold half 60 and a lower mold half 62. Each of theupper mold half 60 and the lower mold half 62 may define a mold surface64 for forming the perimeter seal 52 and the substantially flat, smoothouter surface 32 _(O), 34 _(O) of each of the first barrier sheet 32 andthe second barrier sheet 34. The upper mold half 60 and the lower moldhalf 62 may additionally include a fluid conduit portion 66 that permitsfluid communication with a source of pressurized fluid 68 (see, forexample, FIG. 22) for permitting fluid communication of a pressurizedfluid (e.g., air) from: (1) a source of pressurized fluid 68, (2)through the fluid conduit portion 66 of each of the upper mold half 60and the lower mold half 62, and (3) into the cavity 50 for inflating thecushioning arrangement 30.

As shown in FIGS. 18 and 19, the mold tool 58 is arranged in an openconfiguration by spacing apart the upper mold half 60 and the lower moldhalf 62 to allow the plurality of components 32, 34, 36 defining thecushioning arrangement 30 to be arranged therebetween. As shown in FIGS.20 and 21, the mold tool 58 may then be arranged in a closedconfiguration by arranging the upper mold half 60 adjacent the lowermold half 62, thereby shaping the plurality of components 32, 34, 36defining the cushioning arrangement 30. The components 32, 34, 36 areshaped by applying heat and pressure to the components 32, 34, 36 at themold surfaces 64 of the upper mold half 60 and the lower mold half 62.Application of heat and pressure forms the perimeter seal 52 by fusingthe materials of the barrier sheets 32, 34 together and, further, mayform the first melded portion 46 and the second melded portion 48 toattach the tensile layers 40, 42 to the barrier sheets 30, 32,respectively. As described above, if the tensile layers 40, 42 arerespectively attached to the barrier sheets 30, 32 via an adhesiverather than by melding a material of the elements 32, 34, 40, 42, thelayers 40, 42 are attached to the sheets 30, 32, respectively, by theapplication of heat and/or pressure by the mold surfaces 64 of the uppermold half 60 and the lower mold half 62 to activate the adhesive whenthe mold halves 60, 62 are in the closed configuration.

The source of pressurized fluid 68 may communicate pressurized fluid(e.g., air) from: (1) the source of pressurized fluid 68, (2) throughthe fluid conduit portion 66 of each of the upper mold half 60 and thelower mold half 62, and (3) into the cavity 50 for at least partiallyinflating the cushioning arrangement 30, as shown in FIG. 22.Thereafter, the mold tool 58 may seal the perimeter seal 52 at thelocation of the conduit potion 66 by joining the material of the firstbarrier sheet 32 and the material of the second barrier sheet 34 at thelocation of the conduit portion 66 to seal the pressurized fluid withinthe cavity 50. At this point, the mold tool 58 may be returned to theopen configuration by spacing apart the upper mold half 60 and the lowermold half 62 to allow the cushioning arrangement 30 of FIG. 14 to beremoved from the mold tool 58.

Referring to FIGS. 24-27, a second mold tool 70 is shown for forming thecushioning arrangement 30 of FIG. 17 that is shaped or divided into aplurality of fluid-filled chambers 38 ₁-38 _(n). As shown in FIG. 24,the mold tool 70 includes an upper mold half 72 and a lower mold half74. Each of the upper mold half 72 and the lower mold half 74 may definea mold surface 76 for forming the plurality of fluid-filled chambers 38₁-38 _(n) and the one or more recesses, trenches, or valleys 56.

As shown in FIGS. 24 and 25, the second mold tool 70 is arranged in anopen configuration by spacing apart the upper mold half 72 and the lowermold half 74 to allow the cushioning arrangement 30 that was previouslyformed by the first mold tool 58 to be arranged between the upper moldhalf 72 and the lower mold half 74. After the cushioning arrangement 30is located between the mold halves 72, 74, the mold tool 70 is arrangedin a closed configuration by arranging the upper mold half 72 adjacentthe lower mold half 74, thereby further shaping the cushioningarrangement 30 by forming the one or more third melded portion(s) 54.Specifically, the mold surfaces 76 include a shape that defines thevalleys 56 in the uniform and smooth outer surfaces 32 _(O), 34 _(O) ofeach of the first barrier sheet 32 and the second barrier sheet 34. Theshape of the mold surface 76 may be such that the elongate fluid-filledchambers 38 ₁-38 _(n) of FIGS. 3 and 3B are formed or, alternatively,may be such that fluid-filled chambers 38 ₁-38 _(n) having a hexagonalshape such as shown in FIG. 3A are formed. Further, the mold surfaces 76may include virtually any shape to provide the fluid-filled chamber 38with virtually any pattern.

When the mold halves 72, 74 are moved into the closed configuration, themold surfaces 76 contact respective ones of the outer surfaces 32 _(O),34 _(O) of each of the first barrier sheet 32 and the second barriersheet 34. At this point, heat and pressure are applied to the outersurfaces 32 _(O), 34 _(O) of each of the first barrier sheet 32 and thesecond barrier sheet 34 to provide the outer surfaces 32 _(O), 34 _(O)with a series of one or more recesses, trenches, or valleys 56. Therecesses or valleys 56 are created where the mold surfaces 76 form thethird melded portions 54, whereby materials of the first barrier sheet32, the second barrier sheet 34, the first tensile layer 40, the secondtensile layer 42, and the tensile elements 44 are melded together.

The melded portions 54 can form any pattern in the outer surfaces 32_(O), 34 _(O) of each of the first barrier sheet 32 and the secondbarrier sheet 34 to provide filled chambers 38 ₁-38 _(n), havingvirtually any shape, size, and configuration such as the configurationsshown in FIGS. 3, 3A, and 3B. Further, the melded portions 54 may bespaced apart from the perimeter seal 52 or, alternatively, may be spacedapart from the perimeter seal 52. For example, as shown in FIG. 3, themelded portions 54 defining the valleys 56 extend across the chamber 38from the medial side 22 to the lateral side 24 such that the meldedportions 54 contact and extend from the perimeter seal 52.Alternatively, and with respect to FIG. 3A, some of the melded portions54 defining the individual hexagonal shapes are spaced apart andseparated from the perimeter seal 52 while others contact and extendfrom the perimeter seal 52.

Regardless of the particular configuration of the pattern formed by themelded portions 54, the melded portions 54 are formed becauseapplication of heat at discrete locations of the outer surfaces 32 _(O),34 _(O) of each of the first barrier sheet 32 and the second barriersheet 34 causes the material of the first barrier sheet 32, the secondbarrier sheet 34, the first tensile layer 40, the second tensile layer42, and the tensile elements 44 to be melded together. Melding of thesematerials is possible because these materials are either the same and/orhave the same melting temperature and/or have a melting temperaturewithin approximately 20° C. of one another. Accordingly, when heat of apredetermined magnitude is applied to the outer surfaces 32 _(O), 34_(O) of each of the first barrier sheet 32 and the second barrier sheet34 (i.e., heat that exceeds the melting temperature of elements 32, 34,40, 42, 44), the material of these elements 32, 34, 40, 42, 44 flows andmixes or melds together, thereby forming the melded portions 54.

After formation of the melded portions 54, the mold tool 70 is returnedto the open configuration by spacing apart the upper mold half 72 andthe lower mold half 74 such that the cushioning arrangement 30 of FIG.17 may be removed. The cushioning arrangement 30 is shaped or dividedinto a plurality of fluid-filled chambers 38 ₁-38 _(n) by one or morerecesses, trenches, or valleys 56 via formation of the melded portions54.

While the melded portions 54 are shown and described as formingindividual fluid-filled chambers 38 ₁-38 _(n) that are fluidly isolatedfrom one another, the melded portions 54 could alternatively formfluid-filled chambers 38 ₁-38 _(n) that are in fluid communication withone another. For example, the melded portions 54 that form thefluid-filled chambers 38 ₁-38 _(n) of the cushioning arrangement 30 ofFIG. 17 are described and shown as extending across a width of thechamber 38 between opposite sides of the perimeter seal 52 such thateach fluid-filled chamber 38 ₁-38 _(n) is isolated from one another.These melded portions 54 could be modified such that one or moreportions 54 are spaced apart from the perimeter seal 52, therebypermitting one or more fluid-filled chambers 38 ₁-38 _(n) to be in fluidcommunication with one another.

As described above, the mold surfaces 76 of the second mold tool 70 mayinclude virtually any shape to provide the fluid-filled chamber 38 withvirtually any pattern. A portion of an exemplary fluid-filled chamber isshown generally at 38 _(x1) in FIG. 28. As shown in FIGS. 29-31,corresponding mold surfaces 76 of an exemplary mold tool 70 (see, forexample, FIG. 29) may shape the cushioning arrangement 30 such that thethird spaced apart distance (D3) is not eliminated or not reduced tozero at the region R₅₄ defined by the opposing portions of the innersurface 40 _(I) of the first tensile layer 40 and the inner surface 42_(I) of the second tensile layer 42. Accordingly, although the innersurface 40 _(I) of the first tensile layer 40 and the inner surface 42_(I) of the second tensile layer 42 are closer to another at the regionR₅₄ (in comparison to the second spaced apart distance (D2)), in such aconfiguration, the materials of the first barrier sheet 32, the secondbarrier sheet 34, the first tensile layer 40, the second tensile layer42, and the tensile elements 44 extending therebetween are not meldedtogether (unlike the above-described exemplary configuration at FIG. 16that otherwise defines the third melded portion 54).

Furthermore, as shown in FIG. 28, the region R₅₄ defining thefluid-filled chamber 38 _(x1) may be further defined by one or morerecess, trench, or valley 56. In an example, the outer surface 32 _(O)of the first barrier sheet 32 may be substantially flat or planar at theregion R₅₄ whereas the outer surface 34 _(O) of second barrier sheet 34may define the recess, trench, or valley 56 at the region R₅₄.

The exemplary configuration of the fluid-filled chamber 38 _(x1) mayprovide one or more advantageous functions. In an example, the regionR₅₄ defining the fluid-filled chamber 38 _(x1) may provide flexibilityat one or more regions of the cushioning arrangement 30. Alternatively,or in addition to the mold surfaces 76 of the mold tool 70 forming theregion R₅₄ defining the fluid-filled chamber 38 _(x1), an amount of heatand/or closing pressure of the mold tool 70 may contribute to theformation of the region R₅₄ defining the fluid-filled chamber 38 _(x1).

Although an exemplary cushioning arrangement 30 is described above atFIGS. 9-11 to include: (1) attachment of the outer surface 40 _(O) ofthe first tensile layer 40 of the tensile member 36 to the second innersurface portion 32 _(I-2) of the inner surface 32 _(I) of the firstbarrier sheet 32 by melding the material of the first tensile layer 40and the material of the first barrier sheet 32 to form a first meldedportion 46 (see, for example, FIGS. 11) and (2) attachment of the outersurface 42 _(O) of the second tensile layer 42 of the tensile member 36to the second inner surface portion 34 _(I-2) of the inner surface 34_(I) of the second barrier sheet 34 by melding the material of thesecond tensile layer 42 and the material of the second barrier sheet 34to form a second melded portion 48 (see, for example, FIG. 11), someimplementations of a cushioning arrangement may not include such aconfiguration. For example, as shown at FIGS. 32-37:(1) one or moreportions 32 _(I-2P) (see, for example, FIGS. 32 and 37) of the secondinner surface portion 32 _(I-2) of the inner surface 32 _(I) of thefirst barrier sheet 32 is not attached or melded to the outer surface 40_(O) of the first tensile layer 40 of the tensile member 36 and (2) oneor more portions 34 _(I-2P) (see, for example, FIGS. 32 and 37) of thesecond inner surface portion 34 _(I-2) of the inner surface 34 _(I) ofthe second barrier sheet 34 is not attached or melded to the outersurface 42 _(O) of the second tensile layer 42 of the tensile member 36.As shown in FIG. 37, in such implementations, the non-attachment ornon-melding of the above-described surfaces may be located betweenregions R₅₄ that form third melded portions 54.

The exemplary configuration of the cushioning arrangement 30 describedabove at FIGS. 32-37, may result from one or more of a combination ofnot heating (i.e., not melding) selected portions of the cushioningarrangement 30 when it is placed in the mold tool 58 and applyingadhesive (e.g., a hot melt adhesive) to selected portions of thecushioning arrangement 30 for attaching selected portions of thecushioning arrangement 30 prior to introducing the cushioningarrangement 30 in the mold tool 58. In an example, for forming thecushioning arrangement described above at FIG. 37, an adhesive may bearranged over some of the second inner surface portion 32 _(I-2), 34_(I-2) (as shown, for example, in FIG. 32) of the inner surfaces 32_(I), 34 _(I) of the first barrier sheet 32 and the second barrier sheet34 corresponding to the regions R₅₄ that form third melded portions 54for the purpose of attaching the first barrier sheet 32 and the secondbarrier sheet 34 to the tensile member 36 prior to arranging the firstbarrier sheet 32, the second barrier sheet 34, and the tensile member 36in the mold tool 58. Thereafter, when the cushioning arrangement isinflated within the mold tool 58 while the third melded portions 54 areformed by the mold tool 58, the pressurized fluid introduced into thecushioning arrangement 30 maintains some of the second inner surfaceportions 32 _(I-2P), 34 _(I-2P) of the inner surfaces 32 _(I), 34 _(I)of the first barrier sheet 32 and the second barrier sheet 34 at aspaced-apart distance with respect to each of the outer surface 40 _(O)of the first tensile layer 40 of the tensile member 36 and the outersurface 42 _(O) of the second tensile layer 42 of the tensile member 36.

In another example, although an exemplary cushioning arrangement 30 isdescribed above at FIGS. 9-11 to include: (1) attachment of the outersurface 40 _(O) of the first tensile layer 40 of the tensile member 36to the second inner surface portion 32 _(I-2) of the inner surface 32_(I) of the first barrier sheet 32 by melding the material of the firsttensile layer 40 and the material of the first barrier sheet 32 to forma first melded portion 46 (see, for example, FIG. 11) and (2) attachmentof the outer surface 42 _(O) of the second tensile layer 42 of thetensile member 36 to the second inner surface portion 34 _(I-2) of theinner surface 34 _(I) of the second barrier sheet 34 by melding thematerial of the second tensile layer 42 and the material of the secondbarrier sheet 34 to form a second melded portion 48 (see, for example,FIG. 11), some implementations of a cushioning arrangement may notinclude such a configuration. For example, as shown at FIGS. 38-43:(1)one or more portions 32 _(I-2P) (see, for example, FIGS. 38 and 43) ofthe second inner surface portion 32 _(I-2) of the inner surface 32 _(I)of the first barrier sheet 32 is not attached or melded to the outersurface 40 _(O) of the first tensile layer 40 of the tensile member 36while (2) one or more portions 34 _(I-2P) (see, for example, FIGS. 38and 43) of the second inner surface portion 34 _(I-2) of the innersurface 34 _(I) of the second barrier sheet 34 are attached or melded tothe outer surface 42 _(O) of the second tensile layer 42 of the tensilemember 36 by way of, for example, heating and melding in the mold tool58 as described above at FIGS. 18-23. As shown in FIG. 43, is suchimplementations, the non-attachment or non-melding of the one or moreportions 32 _(I-2P) of the second inner surface portion 32 _(I-2) of theinner surface 32 _(I) of the first barrier sheet 32 with respect to theouter surface 40 _(O) of the first tensile layer 40 of the tensilemember 36 may be located between regions R₅₄ that form third meldedportions 54.

The exemplary configuration of the cushioning arrangement 30 describedabove at FIGS. 38-43, may result from one or more of a combination ofnot heating (i.e., not melding) selected portions of the cushioningarrangement 30 when it is placed in the mold tool 58 and applyingadhesive (e.g., a hot melt adhesive) to selected portions of thecushioning arrangement 30 for attaching selected portions of thecushioning arrangement 30 prior to introducing the cushioningarrangement 30 in the mold tool 58. In an example, for forming thecushioning arrangement described above at FIG. 43, an adhesive may bearranged over some of at least one of the second inner surface portion32 _(I-2) of the inner surface 32 _(I) of the first barrier sheet 32 andthe second inner surface portion 34 _(I-2) of the inner surface 34 _(I)of the second barrier sheet 34 corresponding to the regions R₅₄ thatform third melded portions 54 for the purpose of attaching at least oneof the first barrier sheet 32 and the second barrier sheet 34 to thetensile member 36 prior to arranging the first barrier sheet 32, thesecond barrier sheet 34, and the tensile member 36 in the mold tool 58.Thereafter, when the cushioning arrangement is inflated within the moldtool 58 while the third melded portions 54 are formed by the mold tool58, the pressurized fluid introduced into the cushioning arrangement 30maintains some of the second inner surface portion 32 _(I-2P) of theinner surface 32 _(I) of the first barrier sheet 32 at a spaced-apartdistance with respect to the outer surface 40 _(O) of the first tensilelayer 40 of the tensile member 36.

With respect to the exemplary cushioning arrangements 30 described aboveat FIGS. 32-37 and 38-43, the adhesive (e.g., a hot melt adhesive) maybe provided in any desirable ways or configurations. For example, theadhesive may be provided in the form of a sheet and arranged between ordisposed adjacent any of the outer surface 40 _(O) of the first tensilelayer 40 of the tensile member 36, the outer surface 42 _(O) of thesecond tensile layer 42 of the tensile member 36, the second innersurface portion 32 _(I-2) of the inner surface 32 _(I) of the firstbarrier sheet 32, and the second inner surface portion 34 _(I-2) of theinner surface 34 _(I) of the second barrier sheet 34. In anotherexample, the adhesive may be provided in the form of a cap layer of thebarrier sheet. The cap layer may be a co-extruded cap layer of thebarrier sheet, or may be a laminated cap layer of the barrier sheet. Thecap layer comprising the adhesive may form substantially all of theinner surface 32 _(I) of the first barrier sheet 32. The cap layercomprising the adhesive may form substantially all of the inner surface34 _(I) of the second barrier sheet 34. In another example, the adhesivecould be embedded in the tensile fabric. In such an implementation, theadhesive could be a hot melt yarn (e.g., a monofilament yarn) having apolyester core and a TPU sheath.

Referring to FIGS. 44-49, an exemplary cushioning arrangement is showngenerally at 30 having a tensile member 36 including a first tensilelayer 40, a second tensile layer 42 and a plurality of tensile elements44 extending between and connecting the first tensile layer 40 to thesecond tensile layer 42. The tensile member 36 is substantially similarto tensile members of the cushioning arrangements 30 described abovewith exception to the arrangement of tensile elements 44 extendingbetween and connecting an inner surface 40 _(I) 42 _(I) of the firsttensile layer 40 and the second tensile layer 42. In an example, theplurality of tensile elements 44 are not arranged in a non-parallel oroverlapping relationship. For example, the non-parallel or overlappingrelationship may be defined by as crisscross pattern. The remainingaspects of the tensile member 36 are substantially similar to thetensile member 36 of FIGS. 9-13 and are not described in further detail.

The following Clauses provide exemplary configurations of a fluid-filledchamber and methods for making a fluid-filled chamber, as describedabove.

Clause 1: A fluid-filled chamber comprising: a first barrier sheetformed from a first thermoplastic material; a second barrier sheetattached to the first barrier sheet and formed from a secondthermoplastic material, the first barrier sheet and the second barriersheet cooperating to define an internal cavity; a tensile memberdisposed within the internal cavity and formed from a thirdthermoplastic material; and a first weld that attaches the first barriersheet, the second barrier sheet, and the tensile member together bymelding the first thermoplastic material of the first barrier sheet, thesecond thermoplastic material of second barrier sheet, and the thirdthermoplastic material of the tensile member.

Clause 2: The fluid-filled chamber of Clause 1, further comprising asecond weld that extends continuously around a perimeter of thefluid-filled chamber to define an outer edge of the fluid-filledchamber.

Clause 3: The fluid-filled chamber of Clause 2, wherein the second weldjoins the first barrier sheet and the second barrier sheet.

Clause 4: The fluid-filled chamber of Clause 3, wherein the second weldis spaced apart from the first weld.

Clause 5: The fluid-filled chamber of Clause 3, wherein the first weldcontacts and extends from the second weld.

Clause 6: The fluid-filled chamber of Clause 1, wherein the thirdthermoplastic material of the tensile member is foamed.

Clause 7: The fluid-filled chamber of Clause 1, wherein the tensilemember is formed from a sheet of foamed thermoplastic material.

Clause 8: The fluid-filled chamber of Clause 1, wherein the tensilemember includes a plurality of tensile elements extending between thefirst barrier sheet and the second barrier sheet.

Clause 9: The fluid-filled chamber of Clause 8, wherein the plurality oftensile elements extend between and connect a first tensile layer thatopposes the first barrier sheet and a second tensile layer that opposesthe second barrier sheet.

Clause 10: The fluid-filled chamber of Clause 9, wherein the firsttensile layer is attached to the first barrier sheet and the secondtensile layer is attached to the second barrier sheet.

Clause 11: The fluid-filled chamber of Clause 1, wherein the tensilemember comprises a textile.

Clause 12: The fluid-filled chamber of Clause 11, wherein the textile isa knit textile.

Clause 13: The fluid-filled chamber of Clause 12, wherein the knittextile comprises a first tensile layer, a second tensile layer, andtensile strands extending between and connecting the first tensile layerand the second tensile layer.

Clause 14: The fluid-filled chamber of Clause 13, wherein the firsttensile layer is opposes the first barrier layer and the second tensilelayer opposes the second barrier layer.

Clause 15: The fluid-filled chamber of Clause 14, wherein the firsttensile layer is attached to the first barrier layer and the secondtensile layer is attached to the second barrier layer.

Clause 16: The fluid-filled chamber of any of the preceding clauses,wherein the internal cavity receives a pressurized fluid.

Clause 17: The fluid-filled chamber of Clause 16, wherein thepressurized fluid is air.

Clause 18: The fluid-filled chamber of any of the preceding clauses,wherein the first thermoplastic material, the second thermoplasticmaterial, and the third thermoplastic material comprise one or morethermoplastic polyurethane (TPU) polymers.

Clause 19: The fluid-filled chamber of any of the preceding clauses,wherein a melting temperature of the first thermoplastic material, amelting temperature of the second thermoplastic material, and a meltingtemperature of the third thermoplastic material are all within a rangeof approximately 20° C.

Clause 20: The fluid-filled chamber of any of the preceding clauses,wherein a melting temperature of the first thermoplastic material, amelting temperature of the second thermoplastic material, and a meltingtemperature of the third thermoplastic material are approximately thesame.

Clause 21: The fluid-filled chamber of any of the preceding clauses,wherein at least two of the first thermoplastic material, the secondthermoplastic material, and the third thermoplastic material are formedfrom the same material.

Clause 22: An article of footwear or equipment incorporating thefluid-filled chamber of any of the preceding clauses.

Clause 23: A method of making a fluid-filled chamber, the methodcomprising: receiving a first barrier sheet formed from a firstthermoplastic material; receiving a second barrier sheet formed from asecond thermoplastic material; receiving a tensile member formed from athird thermoplastic material; positioning the tensile member between thefirst barrier sheet and the second barrier sheet; and welding the firstbarrier sheet, the second barrier sheet, and the tensile member togetherat a first weld by melding the first thermoplastic material of the firstbarrier sheet, the second thermoplastic material of second barriersheet, and the third thermoplastic material of the tensile member.

Clause 24: The method of Clause 23, further comprising forming a secondweld that extends continuously around a perimeter of the fluid-filledchamber to define an outer edge of the fluid-filled chamber.

Clause 25: The method of Clause 24, wherein forming a second weld thatextends continuously around a perimeter of the fluid-filled chamberincludes joining the first barrier sheet and the second barrier sheet.

Clause 26: The method of Clause 25, wherein welding the first barriersheet, the second barrier sheet, and the tensile member together at thefirst weld includes spacing the first weld apart from the second weld.

Clause 27: The method of Clause 25, wherein welding the first barriersheet, the second barrier sheet, and the tensile member together at thefirst weld includes contacting the first weld with the second weld suchthat the first weld extends from the second weld.

Clause 28: The method of Clause 23, wherein forming the tensile memberfrom the third thermoplastic material includes forming the tensilemember from a foamed thermoplastic material.

Clause 29: The method of Clause 23, wherein forming the tensile memberfrom the third thermoplastic material includes forming the tensilemember from a sheet of foamed thermoplastic material.

Clause 30: The method of Clause 23, wherein forming the tensile memberfrom the third thermoplastic material includes providing the tensilemember with a plurality of tensile elements extending between the firstbarrier sheet and the second barrier sheet.

Clause 31: The method of Clause 30, wherein providing the tensile memberwith a plurality of tensile elements includes extending the plurality oftensile elements between a first tensile layer that opposes the firstbarrier sheet and a second tensile layer that opposes the second barriersheet, the plurality of tensile elements connecting the first tensilelayer and the second tensile layer.

Clause 32: The method of Clause 31, further comprising attaching thefirst tensile layer to the first barrier sheet and attaching the secondtensile layer to the second barrier sheet.

Clause 33: The method of Clause 23, wherein forming the tensile memberfrom the third thermoplastic material includes forming the tensilemember from a textile.

Clause 34: The method of Clause 23, wherein forming the tensile memberfrom a textile includes forming the tensile member from a knit textile.

Clause 35: The method of Clause 34, wherein forming the tensile memberfrom a knit textile includes forming the knit textile to include a firsttensile layer, a second tensile layer, and tensile strands that extendbetween and connect the first tensile layer and the second tensilelayer.

Clause 36: The method of Clause 35, further comprising positioning thetensile member such that the first tensile layer opposes the firstbarrier layer and the second tensile layer opposes the second barrierlayer.

Clause 37: The method of Clause 36, further comprising attaching thefirst tensile layer to the first barrier layer and attaching the secondtensile layer to the second barrier layer.

Clause 38: The method of any of the preceding clauses, furthercomprising providing an internal cavity of the fluid-filled chamber witha pressurized fluid.

Clause 39: The method of Clause 38, wherein providing the internalcavity with a pressurized fluid includes providing the internal cavitywith pressurized air.

Clause 40: The method of any of the preceding clauses, wherein formingthe first barrier sheet from a first thermoplastic material, forming thesecond barrier sheet from a second thermoplastic material, and formingthe tensile member from a third thermoplastic material includes formingthe first barrier sheet, the second barrier sheet, and the tensilemember from one or more thermoplastic polyurethane (TPU) polymers.

Clause 41: The method of any of the preceding clauses, wherein formingthe first barrier sheet from a first thermoplastic material, forming thesecond barrier sheet from a second thermoplastic material, and formingthe tensile member from a third thermoplastic material includes formingthe first barrier sheet, the second barrier sheet, and the tensilemember from materials having melting temperatures that are all within arange of approximately 20° C.

Clause 42: The method of any of the preceding clauses, wherein formingthe first barrier sheet from a first thermoplastic material, forming thesecond barrier sheet from a second thermoplastic material, and formingthe tensile member from a third thermoplastic material includes formingthe first barrier sheet, the second barrier sheet, and the tensilemember from materials having melting temperatures that are approximatelythe same.

Clause 43: The method of any of the preceding clauses, wherein formingthe first barrier sheet from a first thermoplastic material, forming thesecond barrier sheet from a second thermoplastic material, and formingthe tensile member from a third thermoplastic material includes formingat least two of the first barrier sheet, the second barrier sheet, andthe tensile member from the same material.

Clause 44: Incorporating the fluid-filled chamber of any of thepreceding clauses into an article of footwear or equipment.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or feature ofa particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

What is claimed is:
 1. A fluid-filled chamber comprising: a firstbarrier sheet formed from a first thermoplastic material; a secondbarrier sheet attached to the first barrier sheet and formed from asecond thermoplastic material, the first barrier sheet and the secondbarrier sheet cooperating to define an internal cavity; a tensile memberdisposed within the internal cavity and formed from a thirdthermoplastic material; and a first weld that attaches the first barriersheet, the second barrier sheet, and the tensile member together bymelding the first thermoplastic material of the first barrier sheet, thesecond thermoplastic material of second barrier sheet, and the thirdthermoplastic material of the tensile member.
 2. The fluid-filledchamber of claim 1, wherein the internal cavity receives a pressurizedfluid.
 3. The fluid-filled chamber of claim 1, wherein a meltingtemperature of the first thermoplastic material, a melting temperatureof the second thermoplastic material, and a melting temperature of thethird thermoplastic material are approximately the same.
 4. Thefluid-filled chamber of claim 1, wherein at least two of the firstthermoplastic material, the second thermoplastic material, and the thirdthermoplastic material are formed from the same material.
 5. Thefluid-filled chamber of claim 1, further comprising a second weld thatextends continuously around a perimeter of the fluid-filled chamber todefine an outer edge of the fluid-filled chamber.
 6. The fluid-filledchamber of claim 5, wherein the second weld joins the first barriersheet and the second barrier sheet.
 7. The fluid-filled chamber of claim6, wherein the second weld is spaced apart from the first weld.
 8. Thefluid-filled chamber of claim 6, wherein the first weld contacts andextends from the second weld.
 9. The fluid-filled chamber of claim 1,wherein the tensile member includes a plurality of tensile elementsextending between the first barrier sheet and the second barrier sheet.10. The fluid-filled chamber of claim 9, wherein the plurality oftensile elements extend between and connect a first tensile layer thatopposes the first barrier sheet and a second tensile layer that opposesthe second barrier sheet.
 11. The fluid-filled chamber of claim 10,wherein the first tensile layer is attached to the first barrier sheetand the second tensile layer is attached to the second barrier sheet.12. An article of footwear or equipment incorporating the fluid-filledchamber of claim
 1. 13. A method of making a fluid-filled chamber, themethod comprising: receiving a first barrier sheet formed from a firstthermoplastic material; receiving a second barrier sheet formed from asecond thermoplastic material; receiving a tensile member formed from athird thermoplastic material; positioning the tensile member between thefirst barrier sheet and the second barrier sheet; and welding the firstbarrier sheet, the second barrier sheet, and the tensile member togetherat a first weld by melding the first thermoplastic material of the firstbarrier sheet, the second thermoplastic material of second barriersheet, and the third thermoplastic material of the tensile member. 14.The method of claim 13, further comprising providing an internal cavityof the fluid-filled chamber with a pressurized fluid.
 15. The method ofclaim 13, wherein forming the first barrier sheet from a firstthermoplastic material, forming the second barrier sheet from a secondthermoplastic material, and forming the tensile member from a thirdthermoplastic material includes forming the first barrier sheet, thesecond barrier sheet, and the tensile member from materials havingmelting temperatures that are approximately the same.
 16. The method ofclaim 13, wherein forming the first barrier sheet from a firstthermoplastic material, forming the second barrier sheet from a secondthermoplastic material, and forming the tensile member from a thirdthermoplastic material includes forming at least two of the firstbarrier sheet, the second barrier sheet, and the tensile member from thesame material.
 17. The method of claim 13, further comprising forming asecond weld that extends continuously around a perimeter of thefluid-filled chamber to define an outer edge of the fluid-filledchamber.
 18. The method of claim 17, wherein forming a second weld thatextends continuously around a perimeter of the fluid-filled chamberincludes joining the first barrier sheet and the second barrier sheet.19. The method of claim 18, wherein welding the first barrier sheet, thesecond barrier sheet, and the tensile member together at the first weldincludes spacing the first weld apart from the second weld.
 20. Themethod of claim 18, wherein welding the first barrier sheet, the secondbarrier sheet, and the tensile member together at the first weldincludes contacting the first weld with the second weld such that thefirst weld extends from the second weld.